Fasteners bonded to substrate materials without puncturing the materials

ABSTRACT

Systems and methods are disclosed for fasteners bonded to substrate materials without puncturing the materials. An example fastening system includes a male fastener component and a female fastener. The example male fastener component includes a base plate bonded to a first substrate material without puncturing the first substrate material, and a post integrally formed with the base plate, the base plate and the post formed of a polyurethane material. The example female fastener component includes a housing defining a cavity configured to engage with the post of the male fastener component. The housing is made of the polyurethane material and bonded to a second substrate material without puncturing the second substrate material.

RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Application No.62/355,706, filed Jun. 28, 2016, which is hereby incorporated byreference in its entirety.

TECHNICAL FIELD

This disclosure is directed to fasteners for use with clothing, bags andother accessories using a reusable molded closure design in the form ofa post or other shape that can be directly injected, cast, bonded ormolded onto a surface of the item to be fastened.

BACKGROUND

Traditionally, there are two different types of snaps used to joinfabric or other loose materials: either a post-style or a prong-style.As shown in FIG. 1, the post-style has a shaft that extends through thefabric and the prong-style snap has barbs that penetrate through thefabric. Prong-style snaps attach onto the fabric with capped prong ringon one side and a socket or stud on the other side. Prong-style snapsare usually used on loosely woven or knit fabrics. Post-style snapsattach through the fabric with a capped post and corresponding stud orsocket on the other side. Post-style snaps are usually used on denselywoven and/or natural/synthetic fabrics. Snaps are available in brass,steel, stainless steel and plastics such as nylon and nylon blends. Inboth cases the snaps sandwich the material and due to penetration canweaken the fabric or material in that section. In addition, due to thesandwiching of the cap and socket or stud, you have added materialstack-up height since there is a part on each side of the material.Thus, it becomes problematic if only one side of the material isavailable for mounting due to dimensional and/or comfort constraints.

Snaps are typically measured in ligne units which was used in Franceprior to adoption of the metric system (1 mm=0.4433 ligne). It is stillused today to measure size of watch movements, buttons and ribbons.Thus, with snaps you are limited to ligne sizes and circular snaps. Dueto sizing and shape constraints, typical snaps may not fully attach twomaterials or you may need to use multiple snaps which creates gapsbetween snaps or multiple snaps which creates more work for a user toattach. Snaps can also be ordered based on various force specs but thisbecomes more challenging as the snap becomes smaller in size and if aspecific force is needed, custom tooling and larger production runs arerequired.

Another traditional fastener option used with loose fabrics andparticularly clothing are buttons. However, buttons suffer from some ofthe same issues as snaps discussed above. They require a hole to beplaced through one component of the material such that the button can bepushed through it. Buttons are sewn on, and the sewing often comesundone. Indeed, it is common to provide additional buttons with an itemof clothing because this is such a common failure mode. Moreover, bothbuttons and snaps necessarily become a visible component of the objectbeing fastened because they protrude through the surface. This maydetract from the appearance of decorative fabrics. It would bebeneficial to have a fastening system that does not protrude through thefabric material to be joined—both to protect the material integrity andto keep the fasteners out of sight.

Yet another prior art fastening system is velcro. Typically velcro issewn onto a fabric, once again requiring perforation of the fabric.Alternatively, it is adhered with an adhesive, which may give way andleave a sticky residue. Moreover, velcro gets dirty over time and losesits strength, and also produces an audible sound when being pulled apartthat has become associated with cheap or inexpensive designs.

Traditionally, snaps are rigid parts made of metal or injected-moldedplastic. As disclosed below, the adjustable durometer closure (a)facilitates closures with a variety of durometers that provide a softerbased closure that improves comfort, ease-of-use, and (b) facilitatesseamless integration on a much wider array of fabrics onto which theclosure can be directly injected, casted, bonded or molded. For example,instead of using capped post penetrating the material with acorresponding stud or socket, the adjustable durometer closure may bebonded on the material (such as on the inside surface where it is notvisible during wear) with no penetration.

SUMMARY

The appended claims define this application. The present disclosuresummarizes aspects of the embodiments and should not be used to limitthe claims. Other implementations are contemplated in accordance withthe techniques described herein, as will be apparent to one havingordinary skill in the art upon examination of the following drawings anddetailed description, and these implementations are intended to bewithin the scope of this application

Example embodiments are disclosed for fasteners bonded to substratematerials without puncturing the materials. An example fastening systemincludes a male fastener component and a female fastener. The examplemale fastener component includes a base plate bonded to a firstsubstrate material without puncturing the first substrate material, anda post integrally formed with the base plate, the base plate and thepost formed of a polyurethane material. The example female fastenercomponent includes a housing defining a cavity configured to engage withthe post of the male fastener component. The housing is made of thepolyurethane material and bonded to a second substrate material withoutpuncturing the second substrate material.

An example fastening system a first fastener component and a secondfastener component. The first fastener component is formed onto, viamolding, to a first surface of a flexible material without puncturingthe flexible material. Additionally, the first fastener componentincludes a plurality of posts. The second fastener component is formedonto, via molding, to a second surface of the flexible material withoutpuncturing the flexible material. The second fastener component isconfigured to mate with the first fastener.

An method of fastening two surfaces includes inserting a post of a firstfastening component into a cavity defined by a second fasteningcomponent. The first fastening component is molded onto a first surfacewithout puncturing the first surface and the second fastening componentmolded onto a second surface without puncturing the second surface. Theexample method also includes applying force to the first fasteningcomponent and the second fastening component.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the invention, reference may be made toembodiments shown in the following drawings. The components in thedrawings are not necessarily to scale and related elements may beomitted, or in some instances proportions may have been exaggerated, soas to emphasize and clearly illustrate the novel features describedherein. In addition, system components can be variously arranged, asknown in the art. Further, in the drawings, like reference numeralsdesignate corresponding parts throughout the several views.

FIG. 1 illustrates a post-style snap that has a shaft that requires ahole to penetrate a fabric and a prong-style snap that has barbs thatpenetrate through the fabric.

FIG. 2 illustrates exploded views of snap posts bonded to substrates inaccordance with the teachings of this disclosure.

FIGS. 3A, 3B, and 3C illustrate example straight snap posts.

FIGS. 4A, 4B, 4C, 4D, and 4E illustrate example undercut snap posts.

FIG. 5 illustrates an example ledge post.

FIGS. 6A, 6B, 6C, 6D and 6E illustrate an example set of posts thatdefine an interlocking channel.

FIGS. 7A, 7B, and 7C illustrate various closures based on the posts ofFIGS. 2, 3A, 3B, 3C, 4A, 4B, 4C, 4D, 4E, 5, and 6A, 6B.

FIGS. 8A and 8B illustrate examples of male fastener component bonded toa substrate material.

FIGS. 9A and 9B illustrate examples of female fastener component bondedto a substrate material.

FIG. 10 illustrates an example male fastener component snap fit with acorresponding female fastener.

FIG. 11 illustrates an example fastener component with posts arranged inan array bonded to a substrate material.

FIG. 12 illustrates a male fastener and a female fastener componentbonded to a same substrate material.

FIG. 13 illustrates an example of a male fastener component bonded to asubstrate material with a slot.

FIG. 14 illustrates a connector with both a male component and a femalecomponent connected together.

FIG. 15 illustrates a male fastener component and a female fastenercomponent bonded to a substrate material that, when engaged, form agasket.

FIG. 16 is an example of a fastener bonded with an article.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

As describe below, a mating pair of posts and/or slots (sometimesreferred to as “fastener components”) are bonded directly to a firstsurface of a flexible or semi-rigid material (sometime referred toherein as “fabric” or a “substrate material”) using a molding techniquesuch as compression molding. While the term “fabric” is used, one ofordinary skill in the art will recognize that the invention disclosedherein could be used to join various materials together across numerousapplications. For example, the present invention provides a stronger,more versatile, and more attractive alternative to a velcro bond, andcould be used across essentially the same broad functions for whichvelcro is used (e.g., not just clothing, but numerous applications wheretwo surfaces are to be temporarily joined.)

To form the bond between the fastener components and the fabric, apolyurethane blend is spread on a tool and closed in a vacuum toeliminate air bubbles. The polyurethane blend is placed in an oven to beallowed to cure slightly. The fabric is placed over the tools and placedin a heat press under pressure to finalize curing and bonding thefastener components to the fabric. In such a manner, the posts and/orslots are affixed to the fabric without puncturing the fabric. In someexamples, the posts and/or slots are bonded directly onto the fabric.Alternatively, in some examples, the post and/or slots are integrallyformed with a base plate of the same material that is bonded directlyonto the fabric without puncturing the fabric. In some such examples,the base plate is thin (e.g., less than a millimeter) and flexible toflex with the fabric. In some examples, the base plate of the posts isflexible and the base plate of the slots is rigid. The posts areconfigured to mate with the corresponding slots. In some examples, theposts and slots are configured to press fit together. To press fittogether, the posts are forced under pressure into a slightly smallerdiameter slot and held together by friction. In some examples, the postsand slots are configured to snap fit together. To snap fit together, theposts include a flared lip and the slots are resilient and flexiblyextend to receive and contract around the flared lip. In some examples,an array of posts is configured to mate with a corresponding array ofposts via an interlocking fit. Additionally, the posts may be configuredto mate with a non-flexible slot within an item. For example, the postmay be configured to mate with a universal serial bus (USB) port on acellular phone or speaker to aid retention thereto.

FIG. 2 illustrates exploded views of posts 200 bonded to substrates 202and 204 in accordance with the teachings of this disclosure. The posts200 are formed by applying polyurethane (PU) to a casting mold (notshown). The substrate(s) 202 and 204 are positioned on the casting moldand pressure is applied to the substrate(s) 202 and 204, thepolyurethane, and the casting mold. The pressure cures the polyurethanein the shape of the casting mold (e.g., the posts 200) and adheres thepolyurethane posts 200 to the substrate(s) 202 and 204. In someexamples, the bonding strength of the posts 200 and the substratematerial 202 and 204 is at least 2.5 kilograms per centimeter squared.In some examples, the durometer of the cured posts 200 is 45 Shore A to90 Shore A hardness. In the illustrated example, the substrates includea flexible or semi-rigid substrate material 202 and/or a hot melt film204. In some examples, the posts 200 are bonded to a substrate materialor a combination of substrate materials. For examples, the posts 200 maybe bonded to (a) the flexible or semi-rigid substrate material 202, (b)the hot melt material 204, or (c) a combination of the flexible orsemi-rigid substrate material 202 and the hot melt material 204. Asanother example, the posts 200 may be bonded to the flexible orsemi-rigid substrate material 202 while the flexible or semi-rigidsubstrate material 202 is bonded to the hot melt material 204. Theflexible or semi-rigid substrate material 202 may include any suitableflexible or semi-rigid material, singly or in combination, such asneoprene, leather, cotton, wool, nylon, polyester, polypropylene, rayon,and/or lycra, etc. Additionally, the substrates may be solid, knit, orwoven, etc.

FIGS. 3A, 3B, and 3C illustrate example straight posts 300. The straightposts 300 of FIGS. 3A, 3B, and 3C are examples of posts that mate with acorresponding slot through press fitting. The straight posts 300 are anexample of the posts 200 of FIG. 2. FIG. 2A is a perspective view of anexample straight posts 300. In the illustrated example of 3A, thestraight posts 300 includes a cap 302, a body 304, and a flange 306. Thecap 302 includes a tapered portion so that a base of the cap 302 hasdifferent dimensions than a top of the cap 302. The base of the cap 302and the top of the body 304 of the straight posts 300 have the samecross-section and are the same dimensions. In the illustrated example,the height of the body 304 is greater than the height of the cap 302.However, the ratio of the height of the body 304 and the height of thecap 302 may vary. The flange 306 flares out from a base of the body 304to increase the bonding area between the straight posts 300 and thesubstrate(s) 202 and 204 of FIG. 2 to provide adhesion and strength.FIG. 3B illustrates top views and sides views of the straight posts 300that do not include the flange 306 of FIG. 3A. In the illustratedexamples of FIGS. 3A and 3B, the cap 302 and the body 304 of thestraight posts 300 have a circular, a superellipse (sometimes referredto as a “squircle”), and a hexagonal horizontal cross-section. However,the cap 302 and the body 304 of the straight posts 300 may have anyelliptical, regular polygon, or irregular polygon cross-section. Indeed,the present invention is not limited geometrically like traditionalsnaps, and can instead take on decorative outlines/shapes while stillproviding the desired temporary fastening function.

Additionally, in some examples, the cross-section of the cap 302 and thebody 304 is different from the cross-section of the flange 306. Forexample, the cap 302 and the body 206 may have a hexagonal cross-sectionand the flange 306 may have a circular cross-section. FIG. 3Cillustrated a side view of the straight posts 300. As illustrated inFIG. 3C, in some examples, the straight post 300 is made of differenttypes of polyurethane that have different durometers. In the illustratedexample of FIG. 3C, the cap 302 is made of a first polyurethane layer308 that has a first durometer and the body 304 are made of a secondpolyurethane layer 310 that has a second, different durometer. Forexample, the first polyurethane layer 308 may have a shore durometer of55 and the second polyurethane layer 310 may have a shore durometer of70.

FIGS. 4A, 4B, 4C, 4D, and 4E illustrate example undercut posts 400 withflared lips. The undercut posts 400 are an example of the posts 200 ofFIG. 2. The undercut posts 400 of FIGS. 4A, 4B, 4C, 4D, and 4E areexamples of posts that mate with corresponding slots through snapfitting. In the illustrated example of FIG. 4A, the undercut post 400include a cap 402 and a body 404. In some examples, the undercut post400 also includes a flange 406. In the illustrated example, the base ofthe cap 402 has a larger diameter than the top of the body 404. In theillustrated example of FIG. 4B, the cross-sections of the cap 402 andthe body 404 of the undercut post 400 are rectangles. FIG. 4Cillustrates the undercut post 400 that includes the cap 402 with astraight bevel 408. The difference between the base of the cap 402 andthe top of the body 404 defines an overhang 410 that has a length L.Additionally, the body 404 has a height H. FIG. 4D illustrates theundercut post 400 that includes the cap 402 with a curved bevel 412. Thedifference between the base of the cap 402 and the top of the body 404defines an overhang 410 that has a length L. Additionally, the body 404has a height H. FIG. 3D illustrates the undercut post 400 that includesthe cap 402 with a tapered base 414. The bottom of the tapered base 414matches the top of the body 404. The difference between the top of thetapered base 414 (e.g., the widest portion of the cap 402) and the topof the body 404 defines a length L. Additionally, the tapered base 414tapers at an angle θ.

FIG. 5 illustrates an example ledge post 500. The ledge post 500 is anexample of the posts 200 of FIG. 2. In the illustrated example, theledge post 500 includes a cap 502 and a body 504. In the illustratedexample, the cross-section of the cap 502 is larger than thecross-section of the body 504. Additionally, the body 504 is offset toone of the sides of the cap 502. The ledge post 500 is configured sothat when a first ledge post 506 is bonded to a first substrate 508, anda second ledge post 510 is bonded to a second substrate 512, the firstledge post 506 interlocks with the second ledge post 510.

FIGS. 6A, 6B, 6C, 6D, and 6E illustrate an example set of posts 600 and602 that define an interlocking channel 604. The posts 600 and 602 arean example of the posts 200 of FIG. 2. FIG. 6A illustrates a top view ofa first fastener component comprising a first set of posts 600 bonded toa first substrate 606 to define the interlocking channel 604. FIG. 6Billustrates a cross-section of the posts 600 bonded of the firstsubstrate 606. The posts 600 have a tapered wall 608. FIG. 6Cillustrates second fastener component comprising a second post 602bonded to a second substrate 610. The second post 602 is configured tointerlock with the first posts 600 when the first and second fastenercomponents are connected. FIG. 6D illustrates a cross-section of thesecond post 602. The second post comprises tapered walls 612 configuredto interlock with tapered walls 608 of the first set of posts 600 sothat (a) when a vertical force is applied to the fastener components,the fastener components remain interlocked, and (b) when a horizontalforce is applied to the fastener components, the fastener components,the second post 602 slides in the interlocking channel 604 defined bythe first posts 600. FIG. 6E illustrates a cross-section of the firstsubstrate 606 connected to the second substrate 610 via the first andsecond fastener components. In the illustrated example, the second post602 fits within the interlocking channel 604 defined by the first set ofposts 600.

FIGS. 7A, 7B, and 7C illustrate various closures 700-704 based on theposts 200, 300, 400, 500, 600, and 502 of FIGS. 2, 3A, 3B, 3C, 4A, 4B,4C, 4D, 4E, 5, and 6A, 6B. FIG. 7A illustrates a closure 700 thatdefines a cutout portion 708. In the illustrated example, the cutoutportion 708 is sized so that a body of an undercut post (e.g., theundercut post 400 of FIGS. 4A, 4B, 4C, 4D, and 4E) is movable within thecutout portion 708 and the cap of the undercut post prevents theundercut post 400 from being removed from the closure 700 without theapplication of force. FIG. 7B illustrates a closure 702 definingmultiple slots 710 to accept posts 200 bonded to a substrate 712. Forexample the closure 702 and the substrate 712 may be watch bands orstraps of a baseball cap. This embodiment conveniently allows forclothing items (for example) to be adjusted without tailoring oralterations.

FIG. 7C illustrates a post 704 with a non-geometric shape bonded to afirst substrate (not shown) interlocking with the posts 200 acting as aclosure bonded to a second substrate 714. A non-geometric shape is adecorative or ornamental shape that does not have a defined geometricpattern (e.g., geometric patterns such as a triangle, a rectangle, asquare, a circle, a pentagon, a hexagon, a oval, a parallelogram, atrapezoid, a rhombus, etc.). In the illustrated example, the post 704has an organic shape to snap fit into a path defined by the posts 200.

FIGS. 8A and 8B illustrate examples of male fastener component 800 and802 bonded to the substrate material 202 and 204. FIG. 8A illustratesthe male fastener component 800 that includes posts 804 integrallyformed with a base plate 806. In the illustrated example, the post 804includes a flared lip for snap fitting with a corresponding femalefastener. However, the posts may be any of the example posts 200, 300,400, 500, 600, and 502 of FIGS. 2, 3A, 3B, 3C, 4A, 4B, 4C, 4D, 4E, 5,and 6A, 6B. The base plate 806 is bonded (e.g., via compression molding)to the substrate material 202 and 204. The base plate 806 may be of anydesired thickness. In some examples, the base plate 806 is flexible todeform with the substrate material 202 and 204. In some examples, thebase plate 806 is less than one millimeter (mm) thick. FIG. 8Billustrates the male fastener component 802 without the base plate 806of FIG. 8A. The posts 804 of the male fastener component 802 are bondedto the substrate material 202 and 204 without being otherwise connectedto each other. In this arrangement, even though the posts 804 are notconnected other than via the substrate material, the posts 804 togethercomprise the male fastener component 802.

FIGS. 9A and 9B illustrate examples of female fastener component 900 and902 bonded to a substrate material 202 and 204. FIG. 9A illustrates thefemale fastener component 900 defining cavities 904 configured to acceptposts (e.g, the posts 200, 300, 400, 500, 600, and 502 of FIGS. 2, 3A,3B, 3C, 4A, 4B, 4C, 4D, 4E, 5, and 6A, 6B) to form a snap fit or a pressfit. In the illustrated example, the cavities 904 are configured toaccept a post with a flared lip to form a snap fit. FIG. 9B illustratesthe female fastener component 902. The female fastener component 902comprises housings 906 which define the cavities 904 that are configuredto accept posts. Although, the housings 906 are not connected other thanvia the substrate material, the based 906 together comprise the femalefastener component 902.

FIG. 10 illustrates the example male fastener component 800 snap fitwith the corresponding female fastener component 900. The posts 804 ofthe male fastener component 800 engage with the cavities 904 of thefemale fastener component 900. In the illustrated example, the posts 804have a flared lip and the corresponding cavities are configured toengage with the flared lip to snap fit the male fastener component 800and the female fastener component 900. However, the posts 804 and thecavities 904 may be configured to engage to form a press fit.

FIG. 11 illustrates an example array fastener 1100 with posts 1102arranged in an array bonded (e.g., via compression molding) to thesubstrate material 202 and 204. The posts 1102 are spaced to engageanother array fastener 110 to form an interlocking fit, where flaredlips of the posts 1102 of one of the array fastener 1100 interlock withthe flared lips of the posts 1102 of one of the other array fastener1100.

FIG. 12 illustrates a male fastener component 1200 and a female fastenercomponent 1202 bonded to the same substrate material 202 and 204. Thefastener components 1200 and 1202, when engaged, cause the substratematerial 202 and 204 to form a loop. In some examples, the male fastenercomponent 1200 includes multiple posts to facilitate adjusting the sizeof the loop. FIG. 13 illustrates an example of a male fastener component1300 bonded to the substrate material 202 and 204 defining a slot 1302on an end opposite the male fastener component 1300. When the slot 1302engages with the posts of the male fastener component 1300, the thesubstrate material 202 and 204 to forms a loop, In the illustratedexample, the the male fastener component 1300 includes multiple posts tofacilitate adjusting the size of the loop.

FIG. 14 illustrates a connector 1400 with both a male fastener component1402 integrally formed with a female fastener component 1404. The malefastener component 1402 is on a first end 1406 and the female fastenercomponent 1404 is on the second end 1408. A post 1410 of the malefastener component 1402 is configured to engage with a cavity 1412defined by the female fastener component 1404. In the illustratedexample, the post 1410 of the male fastener component 1402 has a flaredlip configured to snap fit into the cavity 1412. To snap fit, theresilient female fastener component 1404 flexibly extends to receive andcontract around the flared lip.

FIG. 15 illustrates a male fastener component 1500 and a female fastenercomponent 1502 bonded to the substrate material 202 and 204 that, whenengaged, form a gasket. The gasket fills the space between two surfacesto hinder leakage (e.g., fluid, electromagnetic radiation, etc.) intoand/or out of the interior space that the gasket surrounds. The malefastener component 1500 includes a continuous post 1504 that extend fromthe surface of the male fastener component 1500 around the geometry ofthe male fastener component 1500. The female fastener component 1502defines a continuous cavity 1506 configured to engage with thecontinuous post 1504. In the illustrated example, the continuous post1504 of the male fastener component 1500 includes a flared lip to snapfit with the continuous cavity 1506 of the female fastener component1502. In some examples, bodies 1508 of the fastener components 1500 and1502 are formed of a material with a relatively hard durometer and thecontinuous post 1504 of the male fastener component 1500 is formed of amaterial with a softer durometer. In some such examples, the continuouspost 1504 of the male fastener component 1500 is resilient and theflared lip flexibly engages into the continuous cavity 1506 of thefemale fastener component 1502.

FIG. 16 is an example of fastener components 1600 bonded with an article1602. In the illustrated example, the fastener components 1600 are malefastener components. However, the fastener components 1600 may be femalefastener components or a combination of male and female fastenercomponents. The fastener components 1600 are bonded to a surface of thearticle 1602. As a result, the substrate material 202 and 204 is notpunctured. Because the substrate material 202 and 204 is not punctured,the article 1602 may be waterproof or water resistant.

As can be seen from these examples, various geometries are made possibleby the new method of attaching posts to textiles that does not requirethe textile to be pierced. Additionally, this method does not requirethe textile to be reinforced or backed. Additionally, the posts of theillustrated examples facilitate an interface between soft goods (e.g., ahelmet liner) and hard goods (e.g., a helmet). In some examples, thetextile may be worn next to the skin without ameliorating the contact onthe skin of the back of the post-style snap and the prong-style snap.

What is claimed is:
 1. A fastening system comprising: a male fastenercomponent comprising: a base plate bonded to a first substrate materialwithout puncturing the first substrate material; and a post integrallyformed with the base plate, the base plate and the post formed of apolyurethane material; and a female fastener component comprising ahousing defining a cavity configured to engage with the post of the malefastener component, the housing made of the polyurethane material andbonded to a second substrate material without puncturing the secondsubstrate material.
 2. The fastening system of claim 1, wherein the postof the male fastener component is configured to press fit into thecavity of the housing of the female fastener component.
 3. The fasteningsystem of claim 1, wherein the post of the male fastener componentcomprises a flared lip and the base of the female fastener component isresilient and flexibly expands to receive and contract around the flaredlip.
 4. The fastening system of claim 3, where the post of the malefastener component comprises a resilient flared lip that flexiblydeforms to enter the cavity of female fastening component to snap fitinto the cavity of female fastening component.
 5. The fastening systemof claim 1, wherein at least one of the male fastening component and thefemale fastening component is cast onto the respective substratematerial, thereby forming a permanent bond thereto.
 6. The fasteningsystem of claim 6, wherein the at least one of the male fasteningcomponent and the female fastening component is cast onto the respectivesubstrate material via compression molding.
 7. The fastening system ofclaim 1, wherein the base of the post is integrally formed of a firstpolyurethane and a tip of the post is formed from a second differentpolyurethane that has a different hardness than the first polyurethane.8. The fastening system of claim 1, wherein the base plate flexible andis less than a millimeter thick.
 9. The fastening system of claim 1,wherein the post has a non-geometric shape.
 10. A fastening systemcomprising: a first fastener component formed onto, via molding, to afirst surface of a flexible material without puncturing the flexiblematerial, the first fastener component comprising a plurality of posts;and a second fastener component formed onto, via molding, to a secondsurface of the flexible material without puncturing the flexiblematerial, the second fastener component configured to mate with thefirst fastener.
 11. The fastening system of claim 10, wherein the secondfastener component defines a plurality of slots configured to engagewith the plurality of posts via press fitting.
 12. The fastening systemof claim 10, wherein the plurality of posts have flared lips.
 13. Thefastening system of claim 12, wherein the second fastener componentdefines a plurality of slots configured to engage with the plurality ofposts via snap fitting.
 14. The fastening system of claim 12, whereinthe plurality of posts of the first fastener component are arranged in afirst array, wherein the second fastener component comprises a pluralityof posts arranged in a second array, and wherein the plurality of postsof the first fastener component are configured to interlock with theplurality of posts of the second fastener component.
 15. The fasteningsystem of claim 10, wherein the first fastener component comprises abase plate integrally formed with the plurality of posts, the base platebeing flexible to deform in conjunction with the flexible material. 16.The fastening system of claim 12, wherein the second fastener componentcomprises a base plate, and wherein the plurality of cavities aredefined within the base plate.
 17. The fastening system of claim 12,wherein the plurality of posts have non-circular cross-sections.
 18. Amethod of fastening two surfaces, comprising: aligning a post of a firstfastening component with a cavity defined by a second fasteningcomponent, the first fastening component molded onto a first surfacewithout puncturing the first surface and the second fastening componentmolded onto a second surface without puncturing the second surface; andapplying force to press the post of the first fastening component intothe cavity of the second fastening component.
 19. The method of claim18, wherein applying the force to the first fastening component and thesecond fastening component causes the second fastening component toflexibly expand to receive the post, the cavity contracting around the aflared lip of the post.